Polymeric chlorotrifluoroethylene



United States Patent 2,755,267 POLYMERIC CHLOROTRIFLUROETHYLENE Robert W. Fin'holt, Erie, Pa., ass'i'glfor 'to General Electric `Company, a corp'rationfof New York No Drawing. Application Maren 9, 1953, Serial No. 341,373`

6 Claims. (Cl. 260443312) This invention is concerned with s'olid polymeric chlo'rotr'itinr'cethylene of ifnprcved plasticity and stabi'l'ity. More particularly the invention relates Vto a cornposition of matter ycomprising (l) solid lpolyrnni'c chlorotriliuoroethylene and (2) a chlorinated diphenyl einer containing at least three chlorine atcr'ns vinfielearly disposed on vthe phenyl nuclei of the'the.

Polyme'ric chlorotriuoroethyle has 'been found to' have good resistance and chemical rsis'tancead b'c of this is eminently suitable Vfor manly applications 'v/here such properties arev desired. Electrical conductors sinned with polymeric enormement-@mylene vare eap'able lof withstanding temperatures vof 'the order of froM about lf50 to 200 C. 'for long periods of with l change in the physical cha'rfadte'rlst-ics' orthe i'isul'a g proper-'ties of the polymeric 'i sul'atio'n. -Schpolym io material is also highly Adesirable for inany .applic ions y whereva' high softening point is' ail advantage. ji it possible to mold various objects the polymeric chlortriiluorethylene either with or Without fillers to give useful articles which are d'imen'sinally ystafble over a wide temperature range.

Because of its cxtreme chemical resistance and' substantial nisolnbility' in :many of the" common .organic solvents, great diiculty has been experienced' in obtain'- ing the polymeric chlorotriiluoroethylene in usable form whereby it can be employedpfor molding or other applications. VIn the past, relatively high molding temperatures and pressures have beer1`-necessary in order to effectively extrude the polymeric chlorotriiluoroethylene. In addition, 4ith'as beemfound at elevated temperatures the polymerio chlorotrifluor'ethylene tends: to degrade and because of this, the use of the polymeric chlorotrifluoroethylene in various applications at elevated .tempera-tures,- particiilarly aft temperatures labove 175 :to y200 C.,.has' been materially curtailed; l

l ha've now discovered that I am able toiiriprove the" moldabi'lity and' extrudability of polymeric `clrlorcitrii'luoroethylene (-any solid polymer Vthereof-may hey employed) While at the same time improving the stabiliti/'of the polymeric chlorotri-iiuoroethylene fat-elevatedv temperatures.4 The-above results-are attained by incorporatinglin the polymeric Ichlorotriiluoroethylene varyingamounts -of chlorinated diphenyl ether-s in which the phenylnucleiofl the diphenyl1 ether Aare substituted'with at l-lea'st -th-ree and as vhigh as nine or more chlorine atoms.v The chlorinated diphenyl ethers employed in the practice of this invention may be considered -a's corresponding to the general formula Where n is a whole number 'equal to efrom 3io V10, e. g., pentachlorodiphenyl ether; vheirach'lorodplienylether', octachloro'diphenyl etherg-etc.` AMixturesot these'chlorini ated -diphenylothers-.may bef-employed within fthe `scope of rnyl invention Wherei'nfthe average-number of chlorines n 2,755,267 Patented July 17, 1956 rice on the 'phenyl nuclei is equal to 'at least three. Thus, one may 'employ mixtures of chlorinated diphenyl ethers in which a 'predominant effective prolg'ortion (e. g., at least 25 to 50%) of the chlorinated diphenyl ethers contain 'at least three chlorine atonisnon thephenyl nuclei, there being present in the mixture, if desired, other chlorinated diphenyl ethers containing, e. g., less thanthree or more than the nuclearly-'substituted chlorine atoms. In such mixtures, the 'prime requisite is that there be su'iiicien't chlorinated diphenyl ether containing at least thrice chlorine atoms on the phenyl nucleus or nuclei ofvtlieether to 'exert the 'desired effects 'of plasticity and Workabilty at lower temperatures. y

The manner whereby the chlorinated diphenyl ethrs (for brevity hereinafter so designated) vmay bev incorpora'ted in theA polymeric chlorotriuoroethyl'en'e may be varied Widely. One n'rethod comprises mechanically ing' finely dividedA polymeric chlorotriuoroethylene with vchlorinated dphenyl ether. `This may be accom'- piisiiea Lby mixing together' nneiy., divide-d poiymeiic chlorotiiiuoroethylene with the chlorinated diphenyl ether, andhati'ng the miitture toa temperature of about to 200 C. and thereafter subjecting the heated ture' to' vigorous stirring sorv as to intimately disperse the chlorinated diphenyl ether in the polymeric material. In this manner one may obtain molding powders suitable for various molding applications including extruding applications. A slurry may also be formed of nely divided polymeric chlorotriuoroethylene yand the chlorinated diphenyl ether dissolved -in benzene` together with an .additional amo'uht of benzene,- and thereafter yeffecti ng homogen'ization or" the mixture by suitable Wll-knoyvh lle'is. Th'ff, l'l' b ''rzl' fy' B fIV heating the mixture to give an intimately dispersed mixture of the polymerand the chlorinated-diphenyl-ether.

Y 'The amount of vchlorinated diphenylether which may beladded for plasticization `and stabilization purposes may be varied widelimits. Preferably, I employ from aboutl 5 .to 20% of the chlorinated diphenylether b'ased on the weight of the -polymeric chlorotriuoroethylene. l Y n l Y zThe polymeric chlorotriuoroethylene.may be anyone dtthose vusually available on `the market. Generally, the polymeric material is employed in the finely dividedstate, and'for Acoatingvrpurposes (e: g., in formation of slurries) is of anaverage particle sizehofuthe order of from about 0.2 .to .25 microns, preferably `from 0.5 to l5 microns average diameter. Attainment lfof the iinely divided state may be accomplished `by grinding the polymer in a -micropulverizer used for .such purposes. 'ilhereafter, the polymerio chlorotr'iiiuoroethylene together lWith the Vchlorinated diphenyl ether `may be V-mixed `in whatever fashion :In .this example, a" commercially available chlorinated diphenyl ether (sold by Dow- Chemical Company, of Midland, 'Michigan under the name -of Dow 5X) containing an? laverage of 5 Ichlorine atomson' the phenyl nuclei'(essentially'fallthe chlorinated diphenyl ether 'cornprised the ipentachloro-substitiited composition), wasnemplayed' withi solid ipol-ymeric chlorotriuoroethylene (KehF resin imanufacturel by the M. W. Kellogg Company, Iersey City, New Jersey) and the mixture of ingredients molded in accordance with the procedure described below. The polymeric chlorotriiluoroethylene employed comprised one having a no strength temperature (N. S. T.) of 240 C. The N. S. T. value serves as a useful guide in the molding of plastics and has particular applicability to plastics composed essentially of polymeric chlorotrifluoroethylene. The measurement of the N. S. T. value is more particularly described in U. S. Patent 2,617,152, issued November ll, 1952.

Ten percent, by weight, of lthe above-described liquid chlorinated diphenyl ether, based on the weight of the polymer, was mixed with finely divided polymeric chlorotrilluoroethylene having a N. S. T. value of 240 C., and the mixture of the two ingredients was passed repeatedly through a small rubber mill for about five minutes. This formulation was then pressed into sheets using a Carver press employing a platen temperature of about 250 C., a pressure of about 10,000 p. s. i., and a pressing time of about 30 seconds followed by a water quench. Each of the molded sheets was permitted to age at 25 C. and small strips, 11/2" x 1A", were cut off periodically for flex testing. The number of exes (which comprised creasing the strip yby folding it back on itself and then reversing 360) required to break the modified samples in two as well as control samples from which the chlorinated diphenyl ether was omitted, are disclosed in the following Table I.

Table I Polychlorotrlluoroethylene+l% Dow 5x EXAMPLE 2 In this example, a mixture of solid polymeric chlorotrifluoroethylene (N. S. T. 240 C.) and 5%, by weight, Dow x, was extruded over nickel-plated copper wire using a small extruding machine having an overall barrel length of a worm diameter of 1" (the worm being a double shallow thread of continuous pitch), having a self-centering die, and having a small capacity head. The barrel was heated electrically by means of two heating units embedded in an aluminum core surrounding the barrel. The speed of the worm and the speed of the wire capstan could be varied through wide limits. The wire employed in the extrusion was nickel-plated 0.032 solid copper and was preheated before entering the head by an electric furnace. A wire temperature of 100 C. was maintained when operating at approximately l1 feet per minute. A cooling bath using circulating water was located 3" vfrom the die. In the particular run described, the polymer containing 5%, by weight, pentachlorodiphenyl ether was extruded in such a manner that the front barrel temperature was about 225 C. while the rear barrel temperature was about 210 C. In addition, the die temperature was about 320 C. and the wire speed was about 10 feet per minute. The insulation produced in this run was clear, colorless and smooth, and passed the N. S. T. test described in Tentative Inspection Procedure for F-l1l3 Coated Hook-up Wire, July 16, 1951, Squire Signal Corps Laboratories. This wire after heat-aging at 150 C. for three weeks could be bent around its own diameter without evidence of any cracking of the insulation.

Similar extrusions were conducted in the same manner as described in Example 2 above with the exception that instead of using pentachlorodiphenyl ether, there were employed diphenyl ether, pentachlorodiphenyl, diphenyl ether containing two chlorine atoms on the phenyl nuclei (Dow 2x), and diphenyl ether containing an average of nine chlorine atoms on the phenyl nuclei (Dow 9x). The conductor insulated with the diphenyl ether was of poor appearance, as evidenced by the fact that i-t was rough and bubbly, and was therefore not tested further. The wires insulated with the polymer containing the pentachlorodiphenyl and the Dow 2x were smooth, but it was found difficult to control the extrusion, and only short lengths of acceptable wire were obtained in each case. Even with the best appearing wire obtained under such circumstances, heat-aging of these wires at 150 C. and 175 C. for 48 hours, followed by a bend around their 'own diameters resulted in cracking and discoloration of the coatings. In contrast to these results, the extruded wire containing an insulation the polymeric chlorotriiluoroethylene having incorporated therein the diphenyl ether containing an average of nine chlorine atoms substituted on the phenyl nuclei was easy to handle and gave -a wire of very good appearance. After 48 hours heat aging at 150 C., the coating was not cracked when bent on its own diameter; heat-aging for 48 hours at 175 C. caused slight discoloration of the insulation at the nickel interface, but the coating again was not cracked.

EXAMPLE 3 In this example, finely divided polymeric chlorotriuoroethylene (N. S. T. 240 C.) was mixed with a benzene solution of about 5%, by weight, pentachlorodiphenyl ether (based on the weight of the polymeric chlorotriuoroethylene) to form slurry. Thereafter, the benzene was removed to give an intimate dispersion of the polymeric chlorotriuoroethylene and the pentachlorodiphenyl ether. Thereafter this mixture, as well as a control from which the chlorinated diphenyl ether was omitted, was extruded over nickel-plated copper wire of the same type described above in Example 2 employing the identical apparatus more particularly described in the latter example. The following Table II shows the conditions under which the modified and unmodified polymers were extruded. Under the heading Resin Time, the subheading Start means the time required before the resin began to appear at the exit end of the extruding apparatus, while the subheading End means the time required for the entire resin charge to pass through the extruding apparatus.

e Inside the barrel.

It will be noted from an examination of Table II that polychlorotriuoroethylene containing chlorinated diphenyl ether can be more readily extruded than can the unmodified polymer. It was also noted that the presence of the chlorinated diphenyl ether had no deleterious effect on the extruded polymer.

EXAMPLE 4 In this example, mixtures of solid polymeric chlorotriuoroethylene and chlorinated diphenyl ether (Dow 5x) were extruded over nickel-plated 0.032 solid copper wire employing the same equipment as was described in Example 2 with the exception that the wire head and die were attached to the barrel. The wire was preheated before entering the head by an electric furnace. A wire temperature of C. was attained at approximately 11 feet per minute. A cooling bath using circulating water was located 3 from the die while a worm speed of 8 revolutions per' minute was vused throughout -the extrusion. 'Ihe vpolymeric chlorotriuoroethylene vemployed was finely divided material. The following Table III shows the results of extruding both the modified and un- 6 in .tests conducted on sample Numbers 3, 5,'and 6, de`l scribed in Table IQII above showed 'an average of from about 232 to about 239. The specifications for polymeric chlorotriuoroethylene on wire require a minimodifie'd polymeric-chlorotriliuoroethylene over the nickel- 5 mum no strength temperature of 232 C. indicating that plated copper wire, including the conditions of extrusion, all the above-cited materials passed the minimum speciand the properties of the extruded surface before and fications. after heat-aging at 175 C. for varying lengths 'of time. The extruded and insulated wire .shown in sample 3 The method `of adding the chlorinated diphenyl ether was described in Table I-Il above was aged at 150 C. for varied. Inthe case of sample No. 2, the chlorinated di- 10 periods of 4 and 7 days. At the end of the four day phenyl ether was -added to lthe powdered polymeric chloperiod, when the wire was given a bend around its own rotriuoroethylene ataround 120 C., the mixture pressed `diameter, no crazing developed and the nickel Vsurface into small 'disks' and thereaftercrushedto a finely divided appeared to be in good condition, After 7 days at 1.50n state. The extrusion compounds 'employed in sample C., only slight crazirrg developed on a 1 diameter bend, Nos. 3, 4 and 6 were prepared by first heating the chlo- 15 but the 'adhesion of the insulation to the nickel substrate vrinated diphenyl ether to about 1.50 C. and adding the was still good. heated liquid to pellets of pressed polymeric chlorotri- It will, of course, be apparent lto those skilled` in the fluoroethylene, and the entire mixture intimately stirred art in addition to the specific polymeric chlorotriuntil a satisfactory dispersion of the chlorinated diphenyl fluoroethylene employed in the foregoing examples, ether in the polymeric chlorotriuoroethylene had been 2'0 other types of solid polymeric chlorotrifluoro'ethylene attained. The unmodified as well as the mixtures of the may be used without departing from the scope of the polymeric chlorotriiiuoroethylene and the chlorinated diinvention. In the same manner, one may use other phenyl ether were then charged to the extrusion apchlorinated diphenyl ethers as, for instance, chlorinated paratus. diphenyl ethers containing an average of from at least 3 Table Ill Barrel Temp., Hours C. Die Aged, Sample No. Polymer Tgrp., Gondltlonasmade t Condition after aging Front Rear 240N.S.T 260 240 270 Extremely rough None coated only part of 24o 1N. s. 'r.+15% zoo 20o 24o sriietii 64 smootnunchanged. 24o19rs.Xfi.+5%Dow 225 21o 32o Verysmooth 24 D0.

5 24gXN. S.T.+5% Dow 250 205 25o-30o smooth 16 Do. 5b souX. s. T 25o 24o 30o Rough is Cracked. 6 b 30g N. S. 1.|5% Dow 260 240 300 Smooth 16 Smooth, Unchanged.

The sample numbers having the superscrpt a were and up to 10 chlorine atoms nuclearly disposed on the lprepared at a wire speed of 10 ft./min. while the sample number having the superscript b were prepared at a wire speed of 6 ft./mn. In conducting the tests shown in Table III above, it was noted that when the unmodified resin was run at temperatures suitable to give a smooth coating, the insulation cracked after a short heat aging at 175 C. The presence of the chlorinated diphenyl ether permitted lower operating, i. e., extrusion, temperatures while at the same time giving good-heat aging characteristics.

The wires extruded in sample Numbers 3, 5 and 6 were tested for the no strength temperature of the polymer' on the wire according to the modified test described in Tentative Inspection Procedure for F-1113 Coated Hook- Up Wire, July 16, 1951, Squire Signal Corps Laboratories, U. S. A. This test is a modification of the N. S. T. test described in Kel-F Technical Bulletin #2 1-49 issued by the Kellogg Company of New York, New York. In accordance with this test, a 2 tubular piece of the insulation which has been stripped from the conductor is suspended in an electrically heated oven and a weight, determined from the following formula, is suspended from the bottom of the piece of insulation.

(cross section of insulation in inehes2) 0.003

Weight phenyl radicals. Preferably, the number of chlorines advantageously ranges from about 3 to 9 chlorine atoms on the diphenyl ether residue. The disposition of the chlorines around the two phenyl nuclei may be varied; thus the chlorines may all be on one phenyl radical, or they may be symmetrically or unsymmetrically oriented around the two phenyl nuclei. Obviously, the proportions of the polymeric chlorotrifluoroethylene and the chlorinated diphenyl ether may be varied within the limits described previously.

The modied polymeric chlorotrifluoroethylene herein described and claimed may be employed in various applications. Thus, the modified polymeric material may be used in molding applications whereby advantage may be taken of the improved heat resistance and plasticity of the molded product. These molded compositions may be used as gaskets, as encapsulating materials for electrical coils and other electrical devices, etc. One of the main uses of the compositions herein described is for insulating electrical conductors in the manner described in the foregoing examples. Electrical conductors insulated with the polymeric chlorotrifluoroethylene modified with varying amounts of the chlorinated diphenyl ether have good heat resistance and electrical properties. The presence of the chlorinated diphenyl ether permits relatively rapid extrusion at temperatures below those normally required to effect satisfactory extrusion of the unmodified polymeric chlorotrifluoroethylene.

What I claim as new and desire to secure by Letters Patent of the United States is:

1. A solid composition of matter comprising (l) solid polychlorotrifluoroethylene and (2) from 5 to 20%, by weight, based on the weight of (1) of a chlorinated diphenyl ether containing an average of from 5 to 9 chlorine atoms substituted on the phenyl nuclei of the aforesaidy ether intimately incorporated throughout the polychlorotruoroethylene.

2, A solid composition of matter comprising (l) solid polychlorotriluoroethylene and (2) from 5 to 20%, by weight, based on the weight of (l), of pentachlorodiphenyl ether intimately incorporated throughout the polychlorotriuoroethylene.

3. A solid composition of matter comprising (l) solid polychlorotriuoroethylene and (2) from 5 to 20%, by weight, based on the weight of (l), of nonachlorodiphenyl ether intimately incorporated throughout the polychlorotrifiuoroethylene.

4. The process for improving the workability at low temperatures and the plasticity of polychlorotriuoroethylene, which process comprises intimately incorporating in the latter from 5 to 20%, by weight, based on the weight of the polychlorotriuoroethylene, of a chlorinated diphenyl ether containing from 5 to 9 chlorine atoms substituted on the phenyl nuclei, and thereafter molding the mixture of ingredients.

5. The process for improving the workability lat'low` temperatures and the plasticity of polychlorotriuor ethylene, which process comprises intimately incorporating from 5 to 20%, by weight, based on the weight of the polychlorotritluoroethylene, of pentachlorodiphenyl ether, and thereafter molding the aforesaid modified polyehlorotriuoroethylene.

6. The process for improving the workability at low temperatures and the plasticity of polychlorotriuoroethylene, which process comprises intimately incorporat ing from 5 to 20%, by weight, based on the weight of the polymeric chlorotrifluoroethylene, of nonachlorodiphenyl ether, andthereafter molding the latter modified polychlorotriuoroethylene.

References Cited in the le of this patent UNITED STATES PATENTS 2,542,072 Sprung Feb. 20, 1951 

1. A SOLID COMPOSITION OF MATTER COMPRISING (1) SOLID POLYCHLOROTRIFLUOROETHYLENE AND (2) FROM 5 TO 20%, BY WEIGHT, BASED ON THE WEIGHT OF (1) OF A CHLORINATED DIPHENYL ETHER CONTAINING AN AVERAGE OF FROM 5 TO 9 CHLORINE ATOMS SUBSTITUTED ON THE PHENYL NUCLEI OF THE AFORESAID ETHER INTIMATELY INCORPORATED THROUGHOUT THE POLYCHLOROTRIFLUOROETHYLENE. 